CASE 980B Excavator Service Repair Manual Instant Download

1
SERVICE MANUAL Excavator 980B
SERVICE MANUAL Excavator
980B
9-66739
9-66739
1 Trim along dashedlne 2. Slide into pocket on
Binder Spine.

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

TYPES-4
SERVICE MANUAL Excavator
SERVICE MANUAL Excavator
980B
980B
I I I I I I
9-66739
9-66739

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

TYPE 1-4
TYPE 1 -4
2
980B EXCAVATOR TABLE OF CONTENTS
SECTION NO.
FORM NO.
SERIES/SECTION
10 SERIES - GENERAL General Engine
Specifications . .. ...
. 1010 . . . 1020
9-80325 9-76875 9-76115 9-66736 9-66015 9-66735 9-
66735
Detailed Engine Specifications ......... . . . .
Detailed Fuel System Specifications
...............................1030
Maintenance and Lubrication ............... . .
. . 1050
Torque Charts . .. .. .. ........................1
051
General Cleaning Instructions ...................
.................1055
Safety Rules ........................
..........................1056
20 SERIES - ENGINE Engine Diagnosis . EnQneTuneUp
. 2001 2002
9-76365 9-76379
.
.... . . . . .. ...
Cylinder Head, Valve.Train, Backlash and
Adjustment .......................................
...........2015
9-76166 9-76176
Cylinder Block, Sleeves, Pistons and Rods
...........................2025 Crankshaft, Main
Bearings, Flywheel
and Oil Seal Replacement .........................
.............. 2035 Lubricating System .......
...................................... 2046
9-76187 9-76805 9-66736 9-76335 9-76265 9-78235
Air Cleaner .......
. . . . . . .. .
...................2051 . ............. 2055
Cooling System ..
Turbocharger System . . . ..................2065
Turbocharger Failure Analysis ...................
.... ........ 2565
30 SERIES - FUEL SYSTEM Fuel System and Filters
..........................................3010
9-75297 9-74937 9-74959 9-66736
Fuel Injector Pumps ... . . . . . . . .. 3012
Fuel Injectors ...................................
............... 3013 Fuel Tank, Fuel Lines, and
Fuel Storage ............................3052
40 SERIES - HYDRAULICS Hydraulic System
Maintenance ...................................42
01 System Description, Diagnostic Tests and
Checks ........ ............ 4202 Hydraulic
Diagrams After PIN 6204050. System Description,
Tests and Adjustments, and Flowmeter
9-66737 9-66786
Tests After PIN 6204050 .... . ...................
4202, Sup. 1 Hydraulic Pump .............
9-66735 9-66736 9-66736 9-66737 A
....................... ........
4205 ................................4207
Control Valves . .. . . . .
Servicing the Hydreeo Valves .....................
..........4207, Sup. l
Swing Motor Circuit, Swing Motor,
Crossover Relief Valve . . . . . .
.... .......... 4210
9-66736 9-66735 9-66736 9-66736 9-66736 9-66736
Swing Motor - Machines After PIN 6204050
...................4210, Sup. 1
......4211 ...................... ....4212
Hoist Cylinder Circuit .. .. Crowd Cylinder
Circuit ... . . .
Tool Cylinder Circuit ..
..... . . . . .. 4213
Leveler Circuit, Leveler Lock Valve ............
............ 4215
CR Div. 966739 January 1983
' '
CASE CORPORATION
3
SECTION NO.
FORMNO.
SERIES/SECTION
40 SERIES - HYDRAULICS Track Drive Circuits,
Drive Motors,
Drive Range Solenoid Valve, Hydraulic
Swivel and Inner Swivel ........................................4216 9-66736
Power Sensing Valve ............................................4218 9-66T35
Monoblock Valve ...............................................4219 9-66736
Hydraulic Cylinders .............................................4290 9-66736
50 SERIES - TRACK AND SUSPENSION Track Frames
..................................................
5306
9-66736
60 SERIES - POWER TRAIN Final Drive Transmission
and Digging Brake ........................6317
9-66736
80 SERIES - ELECTRICAL System Description and
Troubleshooting ............... ............8002
9-66736 9-66735 9-66736
. . . 8002, Sup. 1 . . .. 8004
Electrical System - After PIN 6204050 ..
Batteries .. . . .... . .. .. Starter, Starter
Solenoid and Magnetic Switches . . . . . .
. . . .
. . . .. 8015
9-72536 9-66736
Alternator ......................................
..............8016
90 SERIES - MOUNTED EQUIPMENT Swing Gearbox and
Brake ........................................9210
Procedure for Assembly of Swing Gear Box 5955769
......... 9210, Sup. l
9-66738 9-66735 9-66735 9-66736 9-66736
Booms and Tool ... .. .
. . ..
.. 9211 . 9215
....... ... .
Carbody and Leveler .... Turntable Swing .
...............9216
4
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Section
1O5S
GENERAL CL.EANING INSTRUCTIONS
Burl. Form 9-66735 Sept. 1976
CASE CORPORATION
6
1055-2
GENERAL CLEANING INSTRUCTIONS
Complete Assemblies
Rubber Parts
Completely assembled components may be steam
cleaned on the outside only, to make for easier
removal and disassembly. All openings and
breathers must be closed or plugged to prevent
possibility of water entering the component.
Clean rubber parts by washing in clean denatured
alcohol. DO NOT use mineral base cleaning
solvents such as acetoiie or paint thinner on any
rubber parts. If a mineral base solvent is used,
the rubber will start to deteroirate and continue
to deteriorate after the part is put back
into service. The continued deterioration of
the rubber could cause the part to fail.
Drying
All parts cleaned must be thoroughly dried
immediately. Use moisture-free compressed air or
soft lintless absorbent wiping rags. The rags
should be free
Rough Parts Rough parts such as housings,
castings, etc., may be cleaned in hot solution
tanks with mild alkali solutions, providing these
parts do not have ground or polished surfaces.
The parts should remain in the tank long enough
to be thoroughly cleaned and heated. This will
aid the evaporation of rinse water. The parts
should be thoroughly rinsed after cleaning to
remove all traces of alkali.
of abrasive materials such as metal filings,
contaminated oil or lapping compound. Bearings may
be dried using compressed air, provided the air
is directed across the bearings to avoid
spinning. Do not spin bearings when drying.
Bearings may be rotated slowly by hand to speed
the drying process.
Finished or Machined Parts
Corrosion Prevention Parts that have been
cleaned, dried, inspected and are to be
immediately reassembled should be coated with a
light oil to prevent corrosion. If these parts
are to be stored for any length of time, they
should be treated with a good RUST
PREVENTIVE and wrapped in special paper or other
material to prevent corrosion.
Parts having ground or polished surfaces such as
gears, bearings, shafts and collars, should be
cleaned in non-flammable solvent.
DO NOT clean machined parts in
IMPORTANT
hot solution tanks with water and alkaline
solutions
such as sodium hydroxide,
orthosilicates or
phosphates.
7
Section 1056
SAFETY RULES
Burl. Form 9 66735 Sept. 1976
CASE CORPORATION
8
10562
SAFETY RULES
9
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13
ti u
14
2001-2
GENERAL INFORMATION

• Before making any repairs or adjustments on an
  engine, a mechanic or technician must properly
  diagnose the trouble.
• Locating the trouble and repairing it is only
  part of the job, a technician must find and
  eliminate the cause of the trouble as well. Too
  many repairs are made with no thought to removing
  the causes that made the repair necessary.
• For any engine to start or perform proper-
• ly, three main requirements must be present.
• FUEL
• COMPRESSION
• IGNITION
• When any of these requirements are not pre- sent
  or limited by qome mechanical reason the engine
  will not start or fails to operate properly
  throughout the power range.
• FUEL. Fuel system problems can be pre- sent
  anywhere from the fuel tank, through the filters
  and injection pump as well as the injec- tors.
  Correct injection pump timing is impor- tant in
  the overall fuel system performance.
• COMPRESSION. Compression on an en- gine is
  related to the breathing function.

Proper compression is affected by the air
cleaner condition, muffler restriction, valve
condition and operation including proper valve
adjustment, cylinder head gaskets condition
of sleeves, rings, pistons, camshaft, and cam-
shaft timing. 3. IGNITION. Ignition is the result
of adequate compression to develop enough heat in
the air charge on the compression stroke to fire
the fuel being injected into the engine
cylinders. Proper spray pattern and atomization
of the fuel by the injector is very important.
Timing the fuel injection pump to the engine to a
pre- cise degree BTDC is a vital requirement for
proper ignition. The engine diagnosis contained
in the fol- lowing pages covers many trouble
symptoms, the causes, and what will be necessary
to re- pair or eliminate the problem. Under
each symptom are listed the most common and re-
occuring problems progressively to the not so
common problems. Locate your problem sym- ptom in
the diagnosis chart and refer to the pages listed
for the probaDle causes and re- medies.
15
2001-2t INSTALLATION INSTRUCTIONS FOR M2O614
TEFLON VALVE SEAL KIT Special Tools Required
M2O617 VALVE GUIDE CUTTING TOOL
M2O624 SEAL INSTALLATION TOOL
VALVE SPRING COMPRESSOR
STEP 3
NOTE FOUR CYLINDER ENGINES REQUIRE TWO M2O614
KITS AND SIX CYLINDER ENGINES REQUIR E THREE
M2O614 KITS.
VALVE KEEPERS
STEP 1
COMPRESS VALVE SPRING AND REMOVE VALVE
KEEPERS. IMPORTANT VALVES, VALVE RETAINERS OR
RO- TATORS AND VALVE KEEPERS SHOULD BE MARK- ED
WHEN REMOVED, TO INSURE THAT THEY WILL BE
REINSTALLED IN THEIR ORIGINAL LOCATION. STEP
4 VALVE STEM SEAL
REMOVE THE CYLINDER HEADS FROM THE EN- GINE,
REFER TO SECTION 2015 FOR HEAD REMOVAL.
STEP 2
INSTALL A VALVE SPRING COMPRESSOR.
REMOVE VALVE STEM SEAL.
16
2001-25
STEP 5
STEP 8
MINIMUM 1/16 WIDE FLAT
REMOVE VALVE ROTATORS OR SPRING RETAINERS.
SPRINGS, SPRING SEATS AND VALVES. STEP 6
CHECft VALVE GUIDE TOP SURFACE, THERE MUST
BE A MINIMUM OF A 1/16 WIDE FLAT AROUND ENTIRE
TOP SURFACE. STEP 9
CLEAN CYLINDER HEAD COMPLETELY, REMOVING ALL
TRACES OF CARBON AND OTHER DEPOSITS.
STEP 7
CLEAN VALVES WITH A FINE POWER DRIVEN WIR E
BRUSH, REMOVING ALL CARBON AND VARNISH DE-
POSITS. BE CAREFUL NOT TO SCRATCH VALVE
STEMS. USE M20617 TOOL IN A ELECTRIC DRILL (IF
RE- QUIRED) TO PROVIDE NECESSARY FLAT AREA ON
VALVE GUIDE. IMPORTANT DO NOT EXCEED 450 RPM
WHEN DRILLING
17
2001-26
STEP 1O
STEP 13
LUBRICATE VALVES WITH CLEAN ENGINE OIL BE- FORE
REINSTALLING INTO CYLINDER HEAD.
USE M20624 TOOL AND PR ESS SEAL DOWN OVER VALVE
GUIDE UNTIL SEAL IS FLUSH WITH TOP OF GU DE
STEP 11
STEP 14
VALVE SPRING SEAT
INSET A CLOSE COIL END
PLASTIC CAP
PLACE PLASTIC INSTALLATION CAP, PROVIDED IN KIT,
ON THE END OF THE VALVE STEM. NOTE CAP PREVENTS
SHARP EDGES ON VALVE STEM GRO- OVES FROM CUTTING
VALVE SEAL. STEP 12 TEFLON VALVE SEAL
INSTALL THE VALVE SPRING. IMPORTANT THE CLOSE
COIL END OF THE SPRING MUST BE IN- STALLED
TOWARDS THE CYLINDER HEAD, SEE INSET
A. in CAREFULLY START VALVE SEAL ON CAP AND
HOLD THUMBS AGAINST WHITE SEAL INSERT TO AVOID
DISLODGING IT, PUSH SEAL DOWN UNTIL SEAL JAC- KET
TOUCHES TOP OF VALVE GUIDE. REMOVE IN- STALLATION
CAP AND SAVE, SINCE IT MUST BE REUSED.
18
2001-27
STEP 1 8
STEP 15
VALVE KEEPERS
INSTALL VALVE ROTATORS OR SPRING RETAINERS.
IMPORTANT ASSEMBLE VALVE ROTATORS WITH THEIR
ORIGINAL VALVES SINCE THEY TEND TO WEAR IN AS A
MATCHED SET.
INSTALL VALVE KEEPERS IN OUTER VALVE STEM GROOVE.
STEP 16
STEP 19
INSTALL VALVE SPRING COMPRESSOR.
STEP 17
REMOVE SPRING COMPRESSOR AND TAP VALVE STEM END
TO SEAT KEEPERS.
VALVE STEM SEAL
STEP 2O
INSTALL TEFLON SEALS ON THE OTHER INTAKE AND
EXHAUST VALVES, FOLLOWING THE PRECED- ING
PROCEDURE.
INSTALL GROOVE.
STEM SEAL IN LOWER VALVE STEM
19
2001-28 STEP 21
REINSTALL CYLINDER HEAD ON ENGINE FOLLOW- ING
PROCEDURE OUTLINED IN SECTION 2015.
NOE The CASE CORPORATioN reserves the
righf to make improvements in design or
changes in specifications at any time
without incurring any obligation to install
them on units previously sold.
20
2002-3
SPECIAL TOOLS
INCH POUND AND FOOT TORQUE WRENCH
A43277 INJECTOR BORE CLEANER (CLAMP TYPE INJECTOR)
COMPRESSION GAUGE ADAPTER BACHARACH 70-314
(D-55B) CLAIVTP TYPE INJECTOR)
A43278 INJECTOR
REMOVAL TOOL ICLAMP TYPE INJECTOR)
6050 COMPRESSION GAUGE ADAPTER
6062 INJECTOR BORE CLEANER
SERVICE KIT 2205 NUDAY CO., 14615 WYOMING
AVE. DETROIT, MICHIGAN. 48238 (SCREW-JN TYPE
INJECTOR)
TAPPET ADJUSTMENT TOOL
DIAL INDICATOR
SPECIFICATIONS FOR TOOLS WHICH MUST BE
MADE Valve Spring Compressor Tool
5.75
.81
14.
7.50
(2) HOLES .812 DI/ STOCK SIZE .25 X 2.00
.56 125
1.00
NOTE ALL DIMENSIONS IN INCHES
21
2002-4
ENGINE TUNEUP PROCEDURE Checking CranJcshaft
Damper Pulley
STEP 1 THE RECOMMENDED CHANGE INTERVAL FOR THE
CRANKSHAFT DAMPER PULLEY IS 2OOO HOURS MAXIMUM.
AT ANY TIME OVER 1500 HOURS. CONSIDER CHANGING
PULLEY AT ANY MAJOR ENGINE OVERHAUL OR TUNE
UP. EVERY SOO HOURS AND AT ENGINE TUNEUP,
VISUALLY INSPECT RUBBER ELEMENT FOR PEEL AREAS OR
RUBBER MISSING. CHECK ALIGNMENT OF THE V MARKS
BETWEEN THE INNER AND OUTER MEMBERS. IF V
MARKS SHIFT, ENGINE TIMING WILL BE OFF AND
DAMPER PULLEY MUST BE REPLACED.
USE BOLT ON TYPE PULLER TO REMOVE PULLEY. REMOVE
VISCOUS DAMPER FROM PULLEY (IF SO EQUIPPED). DO
NOT PULL OR HAMMER ON OUT- SIDE OF PULLEY OR
VISCOUS DAMPER SERIOUS DAMAGE TO PULLEY,
DAMPER, AND RUBBER SLEEVE COULD RESULT.
RUBBER SLEEVE INSET B VISCOUS
DAMPER TORaUE DAMPER-TO-PULLEY
MOUNTING BOLTS 35 TO 42 FT. LBS. FOR 3/8
MOUNTING BOLTS AND 11O TO 132 FT. LBS. FOR 1/2
GRADE MOUNTING BOLTS.
INSET A RUBBE ELEMENT RANKSHAFT DAMPER
PULLEY DETERIORATED RUBBER ALIGNMENT MARKS
(LOCATED ON TIMING GEAR COVER SIDE OF PULLEY)
22
2002-5
Checking Top Dead Center
STEP 2
STEP 5
CRANK ENGINE UNTIL 10 BTDC MARK ON CRANK- SHAFT
PULLEY IS ALIGNED WITH TIMING POINTER.
REMOVE ROCKER ARM ASSEMBLY.
STEP 3
STEP 6
REMOVE BREATHER TUBE.
COMPRESS EXHAUST VALVE SPRING ON NO. 1 CYLINDER
USING FABRICATED TOOL (SEE PAGE
STEP 4
STEP 7
REMOVE VALVE COVER AND GASKET FROM NO. 1 AND NO.
2 CYLINDERS.
REMOVE VALVE KEEPERS
23
2002-6 STEP 8
CRANK ENGINE CLOCKWISE UNTIL
DIAL INDICATOR HAND STOPS MOVING. RESET INDICATOR
TO ZERO.
VALVE ROTATOR
SPRING
REMOVE VALVE ROTATOR, SPRING AND SEAT.
STEP 9
VALVE SEAT
VALVE SEAL
CRANK ENGINE CLOCKWISE UNTIL .010 SHOWS ON DIAL.
SCRIBE A MARK ON CRANKSHAFT PULLEY IN LINE WITH
TIMING POINTER.
KEEP VALVE SEAL IN PLACE TO PREVENT VALVE FROM
FALLING THROUGH VALVE GUIDE IF PISTON IS MOVED
TOO FAR
CRANK ENGINE COUNTERCLOCKWISE PAST ZERO MARK ON
INDICATOR UNTIL .010 SKOWS ON DIAL. AGAIN,
SCRIBE MARK ON CRANKSHAFT PULLEY.
STEP IO
EXHAUST VALVE STEM INSTALL DIAL INDICATOR ON
END OF VALVE STEM WITH VALVE RESTING ON TOP OF
PISTON.
24
2002-T
STEP 13
STEP 11
.OIO
COMPRESS VALVE SPRING USING FABRICATED TOOL.
INSTALL SEAL IN LOWER VALVE STEM GROOVE. INSTALL
VALVE KEEPERS IN OUTER VALVE STEM GROOVE.
HALF THE DISTANCE BETWEEN THESE TWO SCRIBE MARKS
ON CRANKSHAFT PULLEY WILL BE THE TOP DEAD CENTER
(TDC) MARK. IF THE SCRIBE MARKS ARE NOT THE SAME
AS ORIGINAL MARKS ON PULLEY CHECK DAMPER.
STEP 14
STEP 1 2
INSET A CLOSE COIL END
REMOVE SPRING COMPRESSING TOOL. TAP END OF VALVE
STEM TO SEAT KEEPERS.
VALVE SPRING
STEP 15
INSTALL VALVE ROTATOR. VALVE SPRING SEAT
INSTALL SPRING SEAT AND VALVE SPRING. NOTE
IF EQUIPPED WITH VALVE SPRING HAVING ONLY ONE
CLOSE COIL END, PLACE THIS END TOWARD CYLINDER
HEAD, SEE INSET
INS ALL ROCKER ARM ASSEMBLY ONTO CYLINDER HEAD.
25
2002-8
STEP 16
STEP 1 8
TORCtUE ROCKER ARM ASSEMBLY RETAINING NUTS 40 TO
45 FT. LBS.
INSTALL VALVE COVERS AND GASKETS.
STEP 19
STEP 17
TORQUE VALVE COVER NUTS 6O TO 7O IN. LBS.
STEP 26 FOR HOT
ADJUST VALVE TAPPETS. REFER TO FOR COLD SETTING
OR TO STEP 33 SETTING.
STEP 2O
INSTALL BREATHER TUBE AND GASKETS.
26
2002-9
Adjusting Tappets
Cold Setting STEP 24
STEP 21
TIMING POINTER
REMOVE TURBOCHARGER INTAKE ELBOW (IF SO EQUIPPED).
CRANK ENGINE UNTIL TIMING POINTER IS ALIGNED WITH
TDC TIMING MARK ON CRANKSHAFT PULLEY.
STEP 22
STEP 25
REMOVE BREATHER TUBE.
NO. 1 PUSH RODS
STEP 23
CHECK PUSH RODS ON NO. 1 CYLINDER FOR LOOSE-
NESS. IF PUSH RODS ARE LOOSE, NO. 1 CYLINDER IS
AT TDC ON THE COMPRESSION STROKE. IF PUSH RODS
ARE TIGHT, CRANK ENGINE ONE COMPLETE REVOLUTION
AND ALIGN TIMING POINTER WITH TDC MARK ON PULLEY.
\- REMOVE VALVE COVERS AND GASKETS FROM
ALL CYLINDERS.
27
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2002-10
STEP 26
STEP 27
CRANK THE ENGINE OtJE COMPLETE REVOLU- TION AND
ALIGN THE TIMING POINTER WITH THE TDC MARIA ON
CRANKSHAFT PULLEY. CHECK AND ADJUST THE INTAKE
AND EXHAUST VALVES AS POINTED OUT BY THE ARROWS
BELOW. TAPPET CLEARANCE COLD - INTAKE VALVES
.015 EXHAUST VALVES .025 FOUR CYLINDER ENGINES
CHECK AND ADJUST THE INTAKE ANo Ex AuST VALVES AS
POINTED OUT BY THE ARROWS BELOW.
NO. 4 TDC COMPRESSION STROKE
TAPPET CLEARANCE COLD - INTAKE VALVES
.015 EXHAUST VALVES - .025
SIX CYLINDER ENGINES
FOUR CYLINDER ENGINES
NO. 1 TDC COMPRESSION STROKE
NO. 6 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
NOTE AFTER COMPLETING COLD SETTING VALVE
TAPPET ADJUSTMENT PROCEED TO STEP 35.
NO. 1 TDC COMPRESSION STROKE
29
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